A Mini-Project Report

Submitted in
Machine Design Practice-II
On
“Design of Rigid Flange Coupling”
In Mechanical Engineering (6th Semester)

Submitted to:- Submitted By:-

Mr Ajay Kumar Dhanopia Jayesh Soni(060)
(Assistant Professor) Kanishk Maheshwari(065)
Karan Sharma(066)
Krishan Kant Baroliya(068)
Kulkamal Agarwal(069)
Maninder Singh(073)
Department of Mechanical Engineering
Swami Keshvanand Institute of Technology, Management & Gramothan,
Jaipur
Rajasthan Technical University
May-2020
Problem Statement
A mild steel shaft has to transmit 75 kW at 200 rpm. The allowable stress in
the shaft is limited to 45 N/mm​2​ in shear and angle of twist is not exceed 1​o
in the length of 20 cm. calculate the suitable diameter of the shaft. Design
and draw a cast iron flange coupling of protected type of this shaft. Design
will include shafts, flanges, bolts and keys.
Introduction
A coupling is a device used to connect two shafts together at their ends for the
purpose of transmitting power. Rigid flange coupling is designed for heavy loads
or industrial equipment. When joining shafts within a machine, mechanics can
choose between flexible and rigid couplings. The connecting methods for flange
couplings are usually very strong because of either the pressure of the material or
the sometimes hazardous nature of materials passed through many industrial piping
Systems.
Materials and their Properties
Rigid flanges are usually manufactured by casting process technique. The
commonly used material for flange coupling is grey cast iron (ferrous metal-carbon
% between 2.5 to 4) which is characterized by graphite flakes microstructure to
have a grey appearance because it has a good damping capacity compared to other
ferrous metals. The composition of grey cast iron are 2.5-4% carbon, 1-3% silicon
and the rest is iron by weight proportion. It has less tensile strength and good shock
resistance as compared to its compressive strength. Its mechanical properties are
controlled by the size of the graphite flakes which has good wear resistance and
damping capacity.

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Design and Calculations
Step-I: Preliminary Sketch

Figure 1: Preliminary Sketch of Coupling

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Step-II: Selection of Materials and Input Parameters
Shaft Material: Mild Steel
Coupling Material: Cast Iron
Material for Bolt and Key: Mild Steel
Power transmit: 75 kW at 200 rpm
Allowable shear stress in shaft: 45 N/mm​2
Allowable shear stress for key material: 45 N/mm​2
Crushing stress for bolt and key: 160 N/mm​2
Shear stress for bolt material: 30 N/mm​2
Shear stress for cast iron: 8 N/mm​2
Step-III: Calculation
1. Design Torque
T​d​ = Nominal Torque x Service Factor
Service factor is assumed to be 1.25.
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P ower × 60 × 10
N ominal T orque = 2π × rpm

Nominal Torque= 3580986.22 N-mm

T​d​= 1.25 x 3580986.22= 4476232.77 N-mm
2. Shaft Diameter
Based on Strength Criterion,
16 × T d
Induced Shear Stress, τ= πd3

Or d = 79.71 or 80 mm
Based on Rigidity Criterion,
584×T d ×l
d4 = G×Ө , or d= 50.88 or 52 mm
Taking the higher value, d= 80 mm

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3. Other Dimensions of the Coupling
i. Hub Diameter, d​h​ = 2d = 160 mm
ii. Hub Length, l​h​ = 1.5d = 120 mm
iii. Bolt Circle Diameter, D = 3d = 240 mm
iv. Flange Thickness, t = 0.5d = 40 mm
v. Thickness of Protective Rim, t​1​ = 0.25d = 20 mm
vi. Diameter of Spigot and Recess, d​r​ = 1.5d = 120 mm
vii. Outside diameter of Flange, D​o​ = 4d+2t​1​ = 360 mm
4. Design of Hub as Hollow Shaft
16T d ×dh
τ​hub​ = 4 4 = 5.93 MPa < τ​CI (=8MPa)
​
π(dh −d )

5. Design of Bolts
n= Number of bolts= 4
Td × 2
F​tb​ = n×D = 9325.48 N
Shear Failure of bolts:-
πdb 2
F​tb​ = 4 × τb
d​b​ = 19.89 or 20 mm (M20 bolts)
Crushing Failure of bolts:-
F tb
σc = t ×db = 11.65 MPa (<160 MPa)

6. Failure of Key
Key Dimensions: b = 22 mm and h = 14 mm
Length of Key, l​k​ = length of hub = 120 mm
Td
Tangential Force, F tk = d/2 = 111905.82 N
F tk
Shear Stress, τ = b×lk = 42.38 MPa (< 45 MPa)

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 F tk × 2
Crushing Stress, σ = h × lk = 133.22 MPa (< 160 MPa)

7. Failure of Flange by Shearing from Hub

Tangential force on Hub = Shearing Area x τ
Td
d/2 = πdh t × τ , i.e., τ = 2.78 MPa (< 8MPa)

Analysis
There are several methods analysis software’s have been used for analyzing. In this
project, we are using Ansys software for analyzing. Ansys is a leading finite
element analysis software developed by Ansys inc. it uses a friendly graphical user
interface package. In a linear static, we determine the stresses, displacements,
strain and reaction in the fem. The static analysis deals with the computation of
displacement and stress due to static loads refers to loading but doesn’t cause
inertial or damping effects to be significant for consideration in the analysis.
The material used here is grey cast iron, the Poisson’s Ratio of grey cast iron is
0.28 and Young's Modulus is 1.1e+005 Mpa

Material Grey Cast Iron

Nodes 126611
Elements 66427
Mesh Metric None
Type of Element Brick 8 Node 185
​Table 1: Mesh Statistics

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 Figure 2: Mesh Model of the coupling

Object Name Fixed Support Moment

State Fully defined
Scoping method Geometry selection
Geometry 1 Face
Suppressed No
Coordinate System Global Coordinate
System
X Component 0. N·mm (ramped)
Y Component 0. N·mm (ramped)
Z Component 4.7747e+006 N·mm
(ramped)
Table 2: Analysis Settings

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 S. No. Comparison Shear Stress of Crushing Stress
Bolts (MPa) of Bolts (MPa)
1 Theoretical Results 30 160
2 Analytical Results 17.684 123.24
Table 3: Comparison results of bolts

S. No. Comparison Shear Stress of Crushing Stress

Key (MPa) of Key (MPa)
1 Theoretical Results 45 160
2 Analytical Results 11.262 57.458
Table 4: Comparison results of key

S. No. Comparison Shear Stress in Hub

Flange (MPa)
1 Theoretical Results 8
2 Analytical Results 11.262
Table 5: Shear Stress in the Hub Flange
Conclusion
It was found that the stress obtained from the Ansys software is slightly less than
the stress obtained in the theoretical calculation. The shear stress and crushing
results obtained from Ansys was compared with the theoretical calculation as
tabulated. Hence the results obtained from Ansys matches theoretical calculations
so the design is safe.

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References
1. “Design of Machine Elements” by V. B. Bhandari.
2. Maleev and Hartman’s “Machine Design in SI Units”, edited by O.P.
Grover.